Build Protocol

INTRODUCTION – TAMMAR – CUSTOM, CRASH REPLACEMENT & WARRANTY BUILD
As part of Bouwmeester Composites quality control process all built wheels must follow the build protocol and specifications must be strictly adhered to.

This document is designed for an experienced wheel builder who has a sound knowledge of wheel building and is fully trained as a mechanic. This is only to be performed by an approved BC wheel builder.

You may be a very experienced wheel builder however the Tammar rim is going to be quite unique to all builds you have done, this is why it is important you understand some of the design aspects of the rim and the build process is followed so we can assure a quality, durability and a safe outcome for the customer.

 

SOME TIPS BEFORE YOU START
TAMMAR – Things done differently

– The rim has a low profile and using it’s race tuned layup is engineered to be more compliant than other rims. This compliance means spoke tensions have a greater effect on the building process and the quality of the finished wheel. De-stressing spokes during the build is also critical to the build quality.

– With this engineered compliance the spoke type and specifications are critical. Lighter spokes under no circumstances should be used, only use our recommended spokes as listed.

– The rims have a fully molded spoke and nipple interface. This gives the perfect alignment for spoke and nipple, this also means it is critical our lacing pattern and nipple specifications are followed.

– There is a small flat area on the outer edge of the Tammar rim. We reference the trueing stand from this area as there as it is the flattest surface.

– There will be some discretion the builder will need to take to optimise trueness and tension. The spec is a recommendation, small amounts of variance (5%) outside this spec may occur to optimise the overall build.

– There is a small lip as part of our molding process on 4 quarters of the rim edge. When trueing we advise ‘ignore’ the small deviation in the join area and focus on the complete trueness of the wheel build.

 

IMPORTANT NOTICE
Intended Use
– The Tammar v4.8 has the intended use of trail and enduro use. IMPORTANT: Not for down hill use. Under no circumstances is this to be used for down hill bikes or laced into a hub set for this use.

Hub Choice – Bouwmeester has recommendations for hub choices to suit spoke angles and also some lighter weight hubs may not be suited. Before building you set please contact Bouwmeester for their recommendations.

Rider Weight Limit – We recommend for all our rims that the ‘rider weight’ does not exceed 100kg (220lbs). This ‘rider weight’ includes luggage that may be carried by the rider on the bicycle such as but not limited to backpacks etc. For example, a 95kg rider (209lbs) + 10kg (22lbs) luggage would exceed the weight limit.

 

TOOLS REQUIRED
Trueing Stand Equipped with dial gauges
Spoke Key Suit 14 gauge
Spoke Pliers This is critical to prevent spoke wind up
Tension Meter Park Tools, DT Swiss, Hozan – all recommended
Wheel Dish Tool Dial gauge is great, but not critical

BUILD SPECIFICATIONS
Spoke DT Swiss Competition 14/15/14g, Sapim Race 14/15/14g
Thread treatment Teflon based grease, carbon safe. BC use Nulon XL70
Nipple BC 12mm or DT Swiss 12mm, alloy or brass
Lacing pattern 3x front and rear, spokes tucked/weave, orientation see Diagram 1
Logo facing Valve hole

SPOKE TENSIONS & TRUE SPECIFICATIONS
Front non-drive side 120kg/f on higher tension side
Rear drive side 120kg/f on higher tension side
Tension variance -10kg/f (Difference between spokes on a certain side of wheel)
eg. Spec 120kg/f = recommended range 110-120kg/f
Side to side +/- 0.10mm
Up and down +/- 0.10mm
Dish +/- 0.15mm

 

THE BUILD
1. Lace as per specification by following the diagrams below.


LACE & REFERENCE THE WHEEL
2. Reference all the spokes to the base of the thread (Diagram 3)
3. Reference all spokes tips to just flush of nipple slot (Diagram 4). The spokes should be just starting to pull some tension. If at this point they are still very loose, or already quite tight it may be a sign the spoke length is incorrect.

 

PRE-TENSION, ALIGNMENT & DE_STRESS
4. Pre tension as per the above specifications within +/- 0.25mm
5. Check wheel dish
6. Balance spoke tensions to recommended tensions
7. Firmly de-stress wheel using method A and B

 

FINISHING TO FINAL SPECIFICATIONS
IMPORTANT: For this stage it is strictly recommended spoke pliers are used to prevent spoke wind up
8. Tension and true to final specification tolerance
9. Firmly de-stress wheel using method B
10. Tension and true to final target tolerance again.
11. Lightly de-stress wheel using method B

 

THE FINAL TURNS – Completing the wheel build
12. Finish wheel to recommended trueness, dish and tension. At this point this should only 1-3 spokes should need to be turned and adjusted. You may need to repeat steps 11-12 multiple times.

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